
Please be sure to read the whole of this Chapter before carrying out any work on your car. 
SAFETY FIRST! 
You must always ensure that 
safety is the first consideration 
in any job you carry out. A 
slight lack of concentration, or 
a rush to finish the job quickly 
can easily result in an accident, 
as can failure to follow the 
precautions outlined in 
this manual. 
Be sure to consult the 
suppliers of any materials and 
equipment you may use, and 
to obtain and read carefully 
any operating and health and 
safety instructions that may 
be available on packaging or 
from manufacturers 
and suppliers. 
Raising the Car Safely 
ALWAYS ensure that the vehicle is properly supported when 
raised off the ground. Don't work on, around, or underneath 
a raised vehicle unless axle stands are positioned under 
secure, load bearing underbody areas, or the vehicle is driven 
onto ramps, with the wheels remaining on the ground 
securely chocked to prevent movement. 
NEVER work on a vehicle supported on a jack. Jacks are made 
for lifting the vehicle only, not for holding it off the ground 
while it is being worked on. 
ALWAYS ensure that the safe working load rating of any 
jacks, hoists or lifting gear used is sufficient for the job, and 
that lifting gear is used only as recommended by the 
manufacturer. 
NEVER attempt to loosen or tighten nuts that require a lot of 
force to turn (e.g. a tight oil drain plug) with the vehicle 
raised, unless it is safely supported. Take care not to pull the 
vehicle off its supports when applying force to a spanner. 
Wherever possible, initially slacken tight fastenings before 
raising the car off the ground. 
ALWAYS wear eye protection when working under the 
vehicle and when using power tools. 
Working On The Vehicle 
ALWAYS seek specialist advice unless you are justifiably 
confident about carrying out each job. The safety of your 
vehicle affects you, your passengers and other road users. 
DON'T lean over, or work on, a running engine unless it is 
strictly necessary, and keep long hair and loose clothing well 
out of the way of moving mechanical parts. Note that it is 
theoretically possible for fluorescent striplighting to make an 
engine fan appear to be stationary
 -
 double check whether it 
is spinning or not! This is the sort of error that happens when 
you're really tired and not thinking straight. So... 
...DON'T work on your car when you're over tired. 
ALWAYS work in a well ventilated area and don't inhale dust 
- it may contain asbestos or other harmful substances. 
NEVER run the engine indoors, in a confined space or over 
a pit. 
REMOVE your wrist watch, rings and all other jewellery before 
doing any work on the vehicle
 -
 and especially when working 
on the electrical system. 
DON'T remove the radiator or expansion tank filler cap when 
the cooling system is hot, or you may get scalded by escaping 
coolant or steam. Let the system cool down first and even 
then, if the engine is not completely cold, cover the cap with 
a cloth and gradually release the pressure. 
NEVER drain oil, coolant or automatic transmission fluid when 
the engine is hot. Allow time for it to cool sufficiently to avoid 
scalding you. 
ALWAYS keep antifreeze, brake and clutch fluid away from 
vehicle paintwork. Wash off any spills immediately. 
TAKE CARE to avoid touching any engine or exhaust system 
component unless it is cool enough not to burn you.  

Running The Vehicle 
NEVER start the engine unless the gearbox is in neutral (or 
'Park' in the case of automatic transmission) and the hand 
brake is fully applied. 
NEVER run catalytic converter equipped vehicles without the 
exhaust system heat shields in place. 
TAKE CARE when parking vehicles fitted with catalytic 
converters. The 'cat' reaches extremely high temperatures and 
any combustible materials under the car, such as long dry 
grass, could be ignited. 
Personal Safety 
NEVER siphon fuel, antifreeze, brake fluid or other such toxic 
liquids by mouth, or allow contact with your skin. Use a 
suitable hand pump and wear gloves. 
BEFORE undertaking dirty jobs, use a barrier cream on your 
hands as a protection against infection. Preferably, wear 
suitable gloves, available from DIY outlets. 
WEAR IMPERVIOUS GLOVES for sure when there is a risk of 
used engine oil coming into contact with your skin. It can 
cause cancer. 
WIPE UP any spilt oil, grease or water off the floor 
immediately. 
MAKE SURE that spanners and all other tools are the right size 
for the job and are not likely to slip. Never try to 'double-up' 
spanners to gain more leverage. 
SEEK HELP if you need to lift something heavy which may be 
beyond your capability. Don't forget that when lifting a heavy 
weight, you should keep your back straight and bend your 
knees to avoid injuring your back. 
NEVER take risky short-cuts or rush to finish a job. Plan ahead 
and allow plenty of time. 
BE METICULOUS and keep the work area tidy
 -
 you'll avoid 
frustration, work better and lose less. 
KEEP children and animals right-away from the work area and 
from unattended vehicles. 
ALWAYS tell someone what you're doing and have them 
regularly check that all is well, especially when working alone 
on, or under, the vehicle. 
Fire! 
Petrol (gasoline) is a dangerous and highly flammable liquid 
requiring special precautions. When working on the fuel 
system, disconnect the vehicle battery earth (ground) terminal 
whenever possible and always work outside, or in a very well 
ventilated area. Any form of spark, such as that caused by an 
electrical fault, by two metal surfaces striking against each 
other, by a central heating boiler in the garage 'firing up', or 
even by static electricity built up in your clothing can, in a 
confined space, ignite petrol vapour causing an explosion. 
Take great care not to spill petrol on to the engine or exhaust 
system, never allow any naked flame anywhere near the work 
area and, above all, don't smoke. 
Invest in a workshop-sized fire extinguisher. Choose the 
carbon dioxide type or preferably, dry powder but NEVER a 
water type extinguisher for workshop use. 
DON'T disconnect any fuel pipes on a fuel injected engine 
without following the advice in this manual. The fuel in the 
line is under very high pressure
 -
 sufficient to cause serious 
injury. Remember that many injection systems have residual 
pressure in the pipes for days after switching off. If necessary 
seek specialist advice. 
Fumes 
Petrol (gasoline) vapour and that given off by many solvents, 
thinners, and adhesives are highly toxic and under certain 
conditions can lead to unconsciousness or even death, if 
inhaled. The risks are increased if such fluids are used in a 
confined space so always ensure adequate ventilation. Always 
read the maker's instructions and follow them with care. 
Never drain petrol (gasoline) or use solvents, thinners 
adhesives or other toxic substances in an inspection pit. It is 
also dangerous to park a vehicle for any length of time over 
an inspection pit. The fumes from even a slight fuel leak can 
cause an explosion when the engine is started. 
v ,,, Oil;::;s  

Mains Electricity 
Avoid the use of mains electricity when working on the vehicle, 
whenever possible. Use rechargeable tools and a DC inspection 
lamp, powered from a remote 12V battery
 -
 both are much 
safer. However, if you do use mains-powered equipment, 
ensure that the appliance is wired correctly to its plug, that 
where necessary it is properly earthed (grounded), and that the 
fuse is of the correct rating for the appliance. Do not use any 
mains powered equipment in damp conditions or in the vicinity 
of fuel, fuel vapour or the vehicle battery. 
Always use an RCD (Residual Current Device) circuit breaker 
with mains electricity. Then, if there is a short, the RCD circuit 
breaker minimises the risk of electrocution by instantly cutting 
the power supply. 
Ignition System 
Never work on the ignition system with the ignition switched 
on, or with the engine being turned over on the starter, or 
running and you are recommended never to do so. 
Touching certain parts of the ignition system, such as the HT 
leads, distributor cap, ignition coil etc., can result in a severe 
electric shock or physical injury as a hand is pulled sharply away. 
Voltages produced by electronic ignition systems are much 
higher than those produced by conventional systems and could 
prove fatal, particularly to people with cardiac pacemaker 
implants. Consult your handbook or main dealer if in any 
doubt. 
Cooling Fan 
On many vehicles, the electric cooling fan can switch itself on 
even with the ignition turned off. This is especially likely after 
driving the car and parking it before turning off, after which 
heat rises to the top of the engine and turns the fan on, 
suddenly and without warning. If you intend working in the 
engine bay, it's best to do so when the engine is cold, to 
disconnect the battery, or keep away from the fan, if neither of 
these are possible. 
Battery 
Never cause a spark, smoke, or allow a naked light near the 
vehicle's battery, even in a well ventilated area. Highly explosive 
hydrogen gas is given off as part of the charging process. 
Battery terminals on the car should be shielded, since a spark 
can be caused by any metal object which touches the battery's 
terminals or connecting straps. 
IMPORTANT NOTE: Before disconnecting the battery earth 
(ground) terminal read the relevant FACT FILE in Chapter 5 
regarding saving computer and radio settings.) 
When using a battery charger, switch off the power supply 
before the battery charger leads are connected or disconnected. 
If the battery is not of the 'sealed-for-life' type, loosen the filler 
plugs or remove the cover before charging. For best results the 
battery should be given a low rate trickle charge overnight. Do 
not charge at an excessive rate or the battery may burst. 
Always wear gloves and goggles when carrying or when 
topping up the battery. Acid electrolyte is extremely corrosive 
and must not be allowed to contact the eyes, skin or clothes. 
Brakes and Asbestos 
Obviously, a car's brakes are among its most important safety 
related items. ONLY work on your vehicle's braking system if 
you are trained and competent to do so. If you have not been 
trained in this work, but wish to carry out the jobs described in 
this book, we strongly recommend that you have a garage or 
qualified mechanic check your work before using the car. 
Whenever you work on the braking system components, or 
remove front or rear brake pads or shoes: i) wear an efficient 
particle mask; ii) wipe off all brake dust from the brakes after 
spraying on a proprietary brand of brake cleaner (never blow 
dust off with compressed air); iii) dispose of brake dust and 
discarded shoes or pads in a sealed plastic bag; iv) wash your 
hands thoroughly after you have finished working on the 
brakes and certainly before you eat or smoke; v) replace shoes 
and pads only with asbestos-free shoes or pads. Note that 
asbestos brake dust can cause cancer if inhaled; vi) always 
replace brake pads and/or shoes in complete 'axle' sets of four
 -
never replace the pads/shoes on one wheel only. 
Brake Fluid 
Brake fluid absorbs moisture rapidly from the air and can 
become dangerous resulting in brake failure. You should 
change the fluid in accordance with your vehicle manufacturer's 
recommendations or as advised in this book. Never store (or 
use) an opened container of brake fluid. Dispose of the 
remainder at your Local Authority Waste Disposal Site, in the 
designated disposal unit, not with general waste or with waste 
oil. 
Engine Oils 
Always wear disposable plastic or rubber gloves when draining 
the oil from your engine, i) Note that the drain plug and the oil 
are often hotter than you expect. Wear gloves if the plug is too 
hot to touch and keep your hand to one side so that you are 
not scalded by the spurt of oil as the plug comes away; ii) There 
are very real health hazards associated with used engine oil. In 
the words of one manufacturer's handbook "Prolonged and 
repeated contact may cause serious skin disorders, including 
dermatitis and cancer." Use a barrier cream on your hands and 
try not to get oil on them. Always wear gloves and wash your 
hands with hand cleaner soon after carrying out the work. Keep 
oil out of the reach of children; iii) NEVER, EVER dispose of old 
engine oil into the ground or down a drain. In the UK, and in 
most EC countries, every local authority must provide a safe 
means of oil disposal. In the UK, try your local Environmental 
Health Department for advice on waste disposal facilities. 
Plastic Materials 
Many of the materials used (polymers, resins, adhesives and 
materials acting as catalysts and accelerators) contain dangers in 
the form of poisonous fumes, skin irritants, and the risk of fire  

and explosions. Do not allow resin or 2-pack adhesive hardener, 
or that supplied with filler or 2-pack stopper, to come into 
contact with skin or eyes. Read carefully the safety notes 
supplied on the can, tube or packaging and always wear 
impervious gloves and goggles when working with them. 
Fluoroelastomers 
Fluoroelastomers are commonly used for oil seals, wiring and 
cabling, bearing surfaces, gaskets, diaphragms, hoses and '0' 
rings. If they are subjected to temperatures greater than 315 
degrees C, they will decompose and can be potentially 
hazardous. Some decomposition may occur at temperatures 
above 200 degrees C, and it is obvious that when a car has 
been in a fire or has been dismantled with the assistance of a 
cutting torch or blow torch, the fluoroelastomers can 
decompose in the manner indicated above. 
According to the Health and Safety Executive, "Skin contact 
with this liquid or decomposition residues can cause painful and 
penetrating burns. Permanent irreversible skin and tissue 
damage can occur". Damage can also be caused to eyes or by 
the inhalation of fumes created as fluoroelastomers are burned 
or heated. 
After a vehicle has been exposed to fire or high temperatures: 
1. Do not touch blackened or charred seals or equipment. 
2. Preferably, don't handle parts containing decomposed 
fluoroelastomers, but if you must, wear goggles and PVC 
(polyvinyl chloride) or neoprene protective gloves whilst doing 
so. Never handle such parts unless they are completely cool. 
3. Contaminated parts, residues, materials and clothing, 
including protective clothing and gloves, should be disposed of 
by an approved contractor to landfill or by incineration 
according to national or local regulations. Oil seals, gaskets and 
'0' rings, along with contaminated material, must not 
be burned. 
1. Always have a fire extinguisher of the correct type at arm's 
length when working on the fuel system. If you do have a fire, 
DON'T PANIC. Use the extinguisher effectively by directing it at 
the base of the fire. 
2. NEVER use a naked flame anywhere in the workplace. 
3. KEEP your inspection lamp well away from any source of 
petrol (gasoline) such as when disconnecting a carburettor float 
bowl or fuel line. 
4. NEVER use petrol (gasoline) to clean parts. Use paraffin 
(kerosene), white spirits, or, a proprietary degreaser. 
5. NO SMOKING. There's a risk of fire or of transferring 
dangerous substances to your mouth and, in any case, ash 
falling into mechanical components is to be avoided. 
FACT FILE: FOUR WHEEL DRIVE CARS 
• Whenever you have to raise a wheel off the 
ground and turn it by hand, always ensure that 
the opposite-side's wheel to the one being lifted is 
also off the ground and free to turn and that both wheels remaining 
on the ground are held by the parking brake (if possible) and 
securely chocked in both directions. 
• ALWAYS have the gearbox in neutral (or 'N' in the case of 
automatics). In the case of
 some
 4 wheel drive automatics and those 
with permanent 4WD, it is necessary to disengage the 4WD system 
by special means. 
• Consult your handbook or seek advice from your main dealer. 
6. BE METHODICAL in everything you do, use common sense, 
and think of safety at all times. 
ENVIRONMENT FIRST! 
The used oil from the sump of
 just
 one car
 can
 cover
 an
 area of 
water the size of two football pitches, cutting off the oxygen 
supply
 and
 harming swans, ducks, fish and other river lift. 
When you drain your engine oil
 -
 don't oil the drain! 
Pouring oil 
down the 
drain will 
cause 
pollution. It is 
also an 
offense. 
Don't mix used 
oil with other 
materials, such 
as paint and 
solvents, 
because this 
makes 
recycling 
difficult. 
Take used oil 
to an oil 
recycling bank. 
Telephone 
FREE on 0800 663366 to find the location of your nearest oil 
bank, or contact you local authority recycling officer. 
OIL POLLUTES WATER 
USE YOUR BRAIN-
NOT THE DRAIN!  

• Repeat this operation three more times until the 
complete code number has been entered, if the code 
has been entered in correctly LED B will start flashing. 
• Release button A (see illustration
 1B).
 Red LED B 
flashes for 8 seconds indicating the new remote unit's 
code has been stored. 
IMPORTANT NOTE: If the LED does not illuminate 
when remote unit button (illustration 1B, button 
O is pressed, change the remote unit's battery. 
• Insert the emergency key A into the emergency switch 
slot in the glove compartment turn the key to the left to 
switch the alarm off (see inset). 
• Turn the key back towards its original position to 
switch the alarm system back on. 
IMPORTANT NOTE: As the alarm system absorbs 
energy, if you are not planning on using the car 
for a long period of time, turn the alarm exclusion 
key to the off position, so as not to run the vehicle 
battery down. 
• 2. IGNITION SWITCH AND 
STEERING COLUMN LOCK 
IGNITION SWITCH 
2. The ignition/steering column lock key, once inserted 
in the ignition lock, can be placed in any of the 
following four positions: 
• PARK
 -
 With the key in this 
position the side and tail lights 
can be turned on, the steering 
column locked and the keys 
can be removed. Press button 
A to turn the key to PARK. 
• STOP
 -
 When the key is 
turned to the STOP position the steering column will be 
locked, and the keys can be removed. 
• MAR
 -
 This is the driving position. When the key is in 
this position all the electrical devices are energised. 
• AW
 -
 Turning the key to this position starts the 
engine. 
STEERING COLUMN LOCK 
• LOCKING
 -
 To apply the steering wheel lock turn the 
steering wheel slightly to the left or right when the key is 
at STOP or PARK. 
• UNLOCKING
 -
 Rocking the steering wheel gently back 
and forth while turning the ignition key to MAR unlocks 
the steering wheel. 
• 3. PANEL INDICATORS 
INSTRUMENT DISPLAY PANEL 
3. These are the instrument panel warning LED indicators 
for all FIAT Tipo/Tempra models. Your vehicle will only 
have Panel Indicators relevant to your particular car. 
• 4. ELECTRONIC CHECK PANEL 
4. The electronic check panel is not fitted to models 
with basic trim. 
IMPORTANT NOTE: The check panel will not 
indicate if the tail light fuses blow at the same 
time, or if there is a circuit failure within the panel 
display. 
SIDE AND HATCHBACK DOORS 
When the ignition key is at MAR, the check panel LEDs 
g, h, i, I, m and n monitor the light bulbs and fuses. 
LEDs a, b, c, d, and e monitor incomplete closure of 
the side doors and hatchback. 
• Never remove the key when the car is moving. 
If you do, the steering wheel will lock the first 
time you turn it. 
• If the ignition lock has been tampered with or 
shows any sign of damage (e.g. attempted theft), 
have the lock checked at your nearest FIAT 
Service Centre. 
M Choke Oil pressure warning 
Direction indicators (®) Handbrake engaged 
-X: Side lights m Rear window defroster 
10 High beam head 
lights '•y Injection system warning light 
<1* Rear fog lights • Battery warning 
A Hazard warning lights A Seat belts not 
buckled 
m ABS brake warning a Automatic transmission fluid warning 
o Brake pad wear warning a Doors not properly closed 
Turbo pressure warning Trailer direction indicators 
10 Front fog lights a Diesel fuel filter condenstate warning 
•515" Diesel heater/glow •515" plugs 3 
SWITCHING OFF THE ALARM 
1C. Some models 
are fitted with an 
alarm exclusion 
switch, which can 
be found inside 
the glove 
compartment. If 
the alarm is faulty 
or the remote control batteries are flat:  

Fluid levels (if included) are monitored by LEDs f, o and 
p, indicating the levels of the fluid reservoirs. 
A red LED illuminates at the position on the check panel 
corresponding to a side door or a hatchback/tailgate 
that is not properly closed. 
SIDE AND TAIL LIGHTS 
When the side and tail lights are turned on, the check 
panel monitors the light bulbs, fuses and circuits. 
• LED g monitors the front side lights. 
• LED i monitors the tail lights. 
If one of the two fuses protecting the following bulbs 
blows, LEDs g, i, and m illuminate. 
NUMBER PLATE LIGHTS 
• LED m indicates when one or both of the number 
plate light bulbs have burnt out. 
REAR FOG LIGHTS 
• When the fog-guard lights are turned on, LED h 
monitors the light bulbs. 
• When the fuse blows or a circuit malfunction occurs, 
LED h illuminates, but not the panel indicator. 
STOP LIGHTS 
If one or both stop lights burn out, the fuse blows or a 
circuit malfunction occurs, LED I or n illuminates when 
braking. 
• LED n monitors the left stop light. 
• LED I monitors the right stop light. 
If both bulbs burn out at the same time or brake pedal 
switch malfunction occurs, both LEDs I and n 
illuminate. 
ENGINE OIL LEVEL 
• LED f illuminates when the engine oil level is low (key 
at MAR,engine not running). 
The oil level monitoring system does not operate when 
the engine is running. If the oil level warning LED 
illuminates when driving, a circuit sensor malfunction 
has occurred. 
When starting the car on a hill or within 10 minutes of 
switching off the engine the warning light may 
illuminate (event will be stored in system memory). Start 
the engine again on level ground to ensure the oil level 
is sufficient. 
COOLANT 
A low coolant level is indicated by LED o (key at MAR). 
The LED also illuminates when a sensor or circuit 
malfunction occurs. 
WINDSCREEN AND REAR SCREEN WASH LEVELS 
• LED p illuminates (key at MAR) when the level in the 
windscreen or rear screen wash reservoirs are low. 
• The LED also indicates when a circuit or sensor 
malfunction occurs. 
• 5. HE ATI IMG AMD VENTILATION 
CONTROLS 
5A. Air volume control
 -
 Adjust 
the dynamic air flow (fan OFF) 
by turning the knob up to I. 
Continue turning the knob to 
the right to increase the air 
flow (i.e. fan ON). 
5B. Air temperature control -
The temperature will increase 
the further you turn the air 
temperature knob to the right 
(red zone). 
HEATING 
HEAT DISTRIBUTION 
With the air temperature 
knob (56) turned to the 
red zone and the air 
volume control knob (5A) 
turned to the desired fan 
speed, turn the air 
distribution knob (5C) to: 
• 2
 -
 In sunny, cold weather. 
• 3
 -
 For heating to footwell vents. 
• 4
 -
 Demist the windows. 
• Also, turn the air volume control knob (5A) to level II 
or III. 
VENTILATION 
• Turn the air distribution control to 5. 
• Turn the air temperature adjustment knob fully anti-
clockwise to the blue zone. 
• Turn the air volume control knob to the desired fan 
speed. 
• Turn the air distribution control to 5. 
When the car is moving the volume of the air entering 
the passenger compartment can be reduced by turning 
the fan knob to the left of 1. 
DUAL TEMPERATURE 
• Turn the air temperature adjustment knob to an 
intermediate position. 
• Turn the air distribution control knob to 2. 
The temperature decreases the 
further you turn the temperature control knob to the 
left (blue zone). 
Warmer air is delivered to the footwell vents and cooler 
air to the dashboard vents.  

PART F: TORQUE WRENCH SETTINGS 
Key for engine types and sizes: A
 -
 1372cc; B
 -
 1581cc; 
C
 -
 1697cc Diesel; D
 -
 1929cc Diesel; E
 -
 1929cc Turbo Diesel. 
Engine 
Screw retaining caps to crankcase (M10 x 1.25) 
Screw retaining intermediate and central caps to crankcase (M12 x 1.25)... 
Self-locking screw retaining front and rear caps to crankcase (M12 x 1.25) 
Bolt, cylinder head to engine block (M10 x 1.25) 
IMPORTANT NOTE: All torque settings shown in 
Newton-meters (Nm). Bolt, nut or screw sizes in 
brackets in left-hand column. 
Bolt, cylinder head to engine block (M12 x 1.25) 
Bolts, top to bottom cylinder head (M8) 
Nut for connecting rod cap retaining bolt (M9 x 1) 
Screw, connecting rod cap (M10 x 1) 
Screw retaining engine vent to crankcase 
(M8) 
(M8) 
Screw retaining front cover to crankcase 
(MlOx 1.25) 
(M8) 
Bolt retaining rear cover (flywheel side) to crankcase (M6) 
Nut retaining inlet and exhaust ducts to cylinder head 
(M8) 
(M8) 
Screw, flywheel to crankshaft 
(M10x 1.25) 
(M12
 x
 1.25) 
Lower belt cover retaining screw (M8) 
Screw, damping flywheel to drive gear (M8) 
Nut retaining auxiliary drive pulley to crankshaft (M20 x 1.25) 
Screw retaining drive shaft to crankshaft (*) (M14 x 1.5 left) 
Screw, timing gears 
(M10x 1.25) 
(M12x 1.25) 
Belt tensioner retaining bolt 
(M8) 
(M10x 1.25) 
Fixed belt tensioner retaining screw (M10 x 1.25) 
Screw retaining auxiliary component driven gear (oil pump) (M10 x 1.25) 
Nut for camshaft cap retaining stud (M8) 
Nut retaining camshaft and air vacuum pump end mounts (M8) 
Combustion prechamber retaining ring (M32 x 1.5) 
Nut, injection pump stud (M8) 
Screw, injection pump (M8) 
Nut fastening flexible block to coolant pump case (M12 x 1.25) 
Nut, injection pump gear (M12 x 1.75) 
Screw retaining reaction bracket to oil filter support and injection pump (M8). 
Top retaining screw or nut, oil filter support and injection pump (M12 x 1.25) 
Lower retaining screw, oil filter support and injection pump (M10 x 1.25) 
Complete injector (M24 x 2) 
Glow plugs (M12 x 1.25) 
Nuts retaining fuel delivery line to injection pump and injector (M12 x 1.25)... 
Bolt, coolant pump to engine block (M8 x 1) 
Bolt retaining cover and bracket to coolant pump case (M8) 
Oil pressure switch (M14 x 1.5) 
Coolant temperature sender unit 
(M16 x 1.5 tapered) 
(M18x 1.5 tapered) 
Coolant temperature thermal switch (M16 x 1.5 tapered) 
(*) The bolt need not be greased. 
A B C D E Torque (Nm) 
• • 80 
• • • 113 
• • • 113 
• • 40
 +
 90 degrees 
+ 90 deqrees 
• • • 100
 +
 90 degrees 
+ 90 deqrees 
• • 28 
• • 51 
• • • 25 + 50 deqrees 
• • 
• • • 
25 
20 
• • 50 
25 
• 10 
• • 
• • • 
28 
25 
• • 
• • • 
83 
142 
• • 25 
• • • 28 
• • 155 
• • • 190 
• • 
• • • 
83 
118 
• • 
• • • 
25 
44 
• • • 44 
• • 83 
• • • 19 
• • • 19 
• • • 118 
• • • 25 
• • • 25 
• • 80 
• • • 49 
• • • 29 
• • • 98 
• • • 71 
• • • 55 
• • • 15 
• • • 29 
• • • 25 
• • • 23 
32 
• • 
• • • 34 
30 
• • 30 
expert22 fl/i* http://rutracker.org 23  

Thermal valve on inlet manifold 
(M10 x 1.25 tapered) 
(M8 x 1.25 tapered) 
Oil pressure sending unit (M14 x 1.5) 
Oil temperature sender unit (M14 x 1.5 tapered).... 
Oil level sending unit (M12 x 1.25) 
Engine oil sump retaining bolt/nut (M6) 
Screw retaining oil sealing cover to crankcase (M6) 
Nut retaining manifold support bracket (M8) 
Nut retaining turbine to exhaust manifold (M8) 
Air pressure switch on inlet manifold (M12 x 1.5)... 
Power Unit Mounting 
ENGINE SIDE 
Screw (with long flange) retaining flexible block to rail (M8) 
Self-locking nut with plastic ring (for through screw) retaining flexible block 
to engine bracket (M10 x 1.25) 
Screw retaining flexible block supporting bracket to crankcase 
(M10. 1.25) 
(M12 x 1.25) 
Bolt retaining flexible block to engine bracket (M12 x 1.25) 
Bolt retaining power unit suspension link (M10 x 1.25) 
GEARBOX SIDE 
Screw (with wide flange) retaining flexible block to rail (M8) 
Flanged screws retaining support to plate on gearbox (M10 x 1.25) 
Self-locking nut with plastic ring (for through screw) retaining flexible block 
to gearbox side bracket (M10 x 1.25) 
Flanged screw retaining flexible block to gearbox side bracket (M12 x 1.25). 
DIFFERENTIAL SIDE 
Screw with flange unit retaining elastic block to beam (M8) 
Self-locking nut retaining bracket to gearbox support 
(M8) 
(M12 x 1.25) 
Screw retaining bracket brace to support on gear case (M10 x 1.25) 
Screw, rubber block to bracket (M12 x 1.25) 
Exhaust 
Nut retaining flange to exhaust manifold (M8) 
Nuts for bolts fastening collars joining exhaust pipe sections (M10 x 1.25)... 
Bolt retaining exhaust pipe sleeve to turbine (M8) 
Bolt retaining front exhaust pipe section to gearbox (M8) 
Metex joint to nut and stud manifold to plate and spring retainer (M8) 
Nut for bolt anchoring first exhaust pipe section (M8) 
Nut retaining bracket anchoring first exhaust pipe section (M12 x 1.25) 
Screw with normal flange retaining exhaust pipe terminal block 
support bracket (M8) 
Fuel Circuit 
Bolt (with wide flange) retaining tank and fitting to body (M8) 
Ring retaining delivery, recirculation and vent fitting mounts to tank 
(131 x 6-Trapezoid thread) 
Screw (with wide flange) retaining fuel filter support bracket (M8)